Impeller blade support fixture



Sept. 30, 1952 P. T. ANGELL ETAL 2,612,082

IMPELLER BLADE SUPPORT FIXTURE Filed March 51, 1948 2 SHEETSS HEET l fnrenfczrs fierce T AngeZZ (Q Car'Z J'Les/ia -9 gm pfW E Sept. 30, 1952 P. T; ANGELL ETI'AL 2,612,032

V IMPELLER BLADE SUPPORT FIXTURE I Filed March 31, 1948 2 SHEETSSHEET 2 fnrenurs Pierce 2 Argell cfi Carl JLeSha {W my fiatentecl Sept. 30, 195 2 This invention relates to an improved work supporting fixture for machining operations,- and particularlyto anovel-method of fabricating a Work-supporting fixture-for workpieces of complicated-configuration.- 7

In--recent -years, --adequatemachine tools have been developed for effecting the fabrication :of complex shapessuchasthe blades or vanesofan impeller -wheel-by automatic: milling or grinding operations; As is well knownyin thelarger sizes of impeller wheels, it is desirable that such wheels. not be integrally--formed-but rather be 'formed by assemblage of aplurality of blade or vane -ele-'- ments to a mounting-hubportion; While the existing machine \1 tools will readily operate-on a blank to fabricate an individual blade element, so far as-developing the necessary-relative move ments-betwe'en-the rotating cutter and the work= piece-blank-is cncerned,the fabrication of such individual impeller blades-by milling or grinding operations has-been heretofore -seriouslyhandicappeddueto the difiicultyof providing adequate support for the blade during certain-stagesof-"the milling operation. I

The term-impeller blade-- is used herein in a genericsense and is intended to include any' fluid guide vane,.-including;- of course; compressor blades; turbine buckets; and. nozzle vanes.

Impeller blades-are inherently: of thin; deforin= able-construction and; of course; the' active sur-' facesofisn'ch blades are necessarily of veryconi plex c'onfiguration in order to achieve optimuin adiabatic "efficiency; Since a *mounting; element in the form of a threaded stud or a dove ta'i-led projection is provided only at one end ofthe blade, it was therefore'only possible to support the blade I in a conventional -machine tool fixture by such mounting element. Due to this type of cantilever support;- the general geometry of the blade; and the fact'thatsuch-blades arecom monly formed from aluminum-, magnesium or alloys of suchlightmetals; it has "been: imperative that substantial lateral supportbe impartedto one--face of the-blade-during machining *operations on the otherfacet Obviouslxwhen-startinglwith a generally rectangular blank,- nodifilculty'will be encountered in providing sucl'i support during the milling or grinding operation by whichon of 'tneo'ompiex blade-surfaces is formed. However; when it becom'es time to machine the oppositefaceof th'eblade, thensubs'tantial dili'i ciilties' inadequately supporting the blade durin such machining tperatidn are: encountered. The "geometryarr in tefiar of'theblad makes it sum cienuy flexible tharsubstannarinaeeurae untne comin (01; eon-. Y

Abali it ililai bbjl, 0i." thisVililVel l'tifiriis 0 131 5- Vid al 'lnthbd- Of fabiiafiihg' ax mabh inffddl fixtiii if 61 accurately supporting a com lexsurfac of successive workpieces bycastingof alow melt-I- mg temperature material into aspace defineugon the worksupporting'lblock' betweena rigid back ing' element secured to such block -and a master workpiece having'a contour corresponding to that ontheworkpiece which the fixtureis required to support 3, v l l,

Still another object ofthe invention isto mvide an improved method-"for momma a com plex workpieca; such asan impeller'bla'de. 1 l p The specific nature of the inventiom as-well as other objects and advantages thereof will become apparent to those skilled-in the art from thelfollowing detailed description of the annexed-sheets of drawings which by way of preferredeXainple only illustrateone specific-embodiment of=the-inotiqh=- Figure '--1 is a perspective view, illustratinge a conventional worksupporting fixture 161- amachine tool a-nd the-yarious-elements required'to producea' work-fixing: according-- to the methods of thisinvention; -mc1udin backing element, a master-'workpiece and'a dam meniber 1 nigui-s-z-"is afho izontai sections; "view niustrafl mg maraaucnsnr lie -backing lenient; inasterplate and idanidiirintlicatinbgier 1on; 1

Figure 351sa perspective view or af empreca work ,supportinrnxture"emboayin g th tidn -i11ustratmg=-tne- 'inanrif' of coupe an suchfrniic'tui'e with'the comp x' s'ilff'il of apar; tiallyfmachined work rec d 1 3 Figure 4 is'a "view simnar to igureja terms:- tr'ating thepos'itionof the worksuppoftin'g ure emb odyi'n'g' this invention? uurifigfithfinnai nia chining operation "on 'theiirorkpief" w As shown on the drawings:

As the description proceeds, it will be apparent to those skilled in the art that the principles of this invention are applicable to many other types of workpieces other than the specific example of an impeller blade herein described. Furthermore, the invention is independent of the particular construction of the Work support block or primary work holder upon which a fixture embodying this invention is fabricated.

The invention will be particularly described and illustrated in connection with the formation of a work engaging support upon a machine tool work holder of a well known type which comprises a block element It in which is centrally mounted a chuck unit II which in this example is of the type permitting a cylindrical or threaded shank portion of the workpiece to be clampingly engaged and the workpiece thus supported in cantilever relationship with respect to the support block I0. Since the chuck II is of conventional construction; the elements thereof will not be described in detail, except to point out that the jaws of the chuck may be manually released or engaged with the cylindrical or threaded shank portion of the workpiece by actuation of the knurled knob portion Ila.

As previously mentioned, for exemplary purposes the invention will be described in connection with the fabrication of a work supporting fixture for an impeller blade. As the first step of the method embodying this invention, a master impeller blade I2 is provided. Such blade is of well known construction, having opposed complex vane surfaces I2a and I21: and a cylindrical, threaded shank portion I2c which is rigidly engaged and supported by the chuck II. For the purposes of this invention, it is only necessary that one of the complex surfaces of the master blade, for example, the vane surface IZa, be accurately formed to conform to the machined configuration of similar surfaces on the various vane workpieces which are to be supported in the fixture.

It should be distinctly understood that the invention is independent of the configuration of the mounting shank portion of the blade. Actually, the chucking device Il may be such as to incorporate any root fastening means, such as a dovetail, hinge joint or fir tree.

As a second step in the method of this invention, a rigid backing element is adjustably secured to the support block III with a portion thereof disposed in spaced, generally parallel relationship with respect to the master complex surface I2a. Such backing element may conveniently comprise an L-shaped member I3 which has projecting gibs I30 formed on one arm I3a thereof which are respectively slidably engaged in a radially extending slideway provided adjacent the face of support block I by the securement thereto of a pair of generally planar spaced guides I4. A similar pair of guide members I4 maybe provided on block III in diametrically opposed relationship to accommodate the backing element I 3 in the event that the opposite surface of the master blade, namely the vane surface I2!) is to be utilized as the master complex surface. The other arm I3b of the backing element I3 is disposed in generally perpendicular relationship to the face of the support block It and hence extends in generally parallelism with the master complex surface I2a (as well as a plane passing through the master blade and generally parallel to the surfaces I2a and I2b).

The frontal generally planar face of the arm I3b, which is opposed to the master complex surface I2a, is recessed in any convenient manner, such as by the dovetailed recess I3d for a purpose that will be later described. The base arm I311 of the backing element I3 is further provided with an elongated slot I 3e and a bolt I1 passing through such slot into a threaded hole Na in the support block I0 permits the backing element I3 to be rigidly secured to the support block III in any desired radial position, and hence in any desired spacing with respect to the location of they master workpiece I2.

Next a dam member I5 is provided to cooperate with the master workpiece I2 and the backing element I3 so as to enclose the space defined therebetween. For exemplary purposes, the dam I5 is shown as comprising a U-shaped member of sheet material which is suitably dimensioned so as to surround both the upstanding arm I3b of the backing element I3 and the master workpiece I2.

When the dam is thus disposed, the space between the backing element and the master workpiece is completely filled by a casting operation wherein molten material of relatively low temperature melting point is poured into such space. The dam l5 functions, of course, to assist in confining the molten material to the space between the backing element and the master workpiece. The casting material I6 may comprise any one of several well known forms of low melting point materials which are solid at ambient temperatures. Preferably, it is preferred to employ a low melting point metallic alloy of the type that is commercially available and has melting point in the vicinity of 200 F. In any event, a solid matrix I 6 of the low melting point material is thus formed to fill up the space between the backing element I3 and the master workpiece I2. By virtue of the dovetailed recess 13d formed in the front face of the backing element l3 such matrix is rigidly secured to the backing element.

Furthermore, the frontal face IGa (Figure 3) of the matrix I 6 which abuts the master complex surface I2a of the master workpiece I2 will exactly conform to the configuration of such surface with a high degree of accuracy. Therefore, at the conclusion of the casting operation and after the molten material I6 has solidified, the ram I5 may be removed from block In, as well as the master workpiece I2, whereupon the matrix I6 will appear as shown in Figure 3 with the exposed face Ifia thereof conforming exactly to the master complex surface I2 of the master workpiece.

In the event that it is necessary to radially shift the backing element I3 in order to effect the removal of the. master workpiece I2 from the support block II], the slideway defined by the guides I4 insure that the backing element I3 may be positioned in exact relationship with respect to the axis of the chuck II as it previously occupied during the casting operation.

In the normal sequence of use of the support element including the matrix IS, a blade blank is employed having fiat sides and a suitable root fastening projection thereon, and this blank is secured to the block ID by insertion of the root fastening means in the chuck II. A fiat-sided fixture, for example, a fixture similar to the backing element I3 before the casting of the matrix I6 thereon, is mounted in one of the sets of guides I4 on the block I0 and engaged against one of the flat sides of the blade blank. There- 5 after the:exposedrsiiierof- 'thebiadeeiszmacrfined to its GOIIIIJI'GX'OOIIfiOUICT-in this mannemathe plex surface may; ibe .machinedzsto very; .close tolerances 7 relative to the :center of gravitytof theiro'ot fastening means :of therparticular. blade. Then, without removingrithe'. blade'afrom the chuckl I, a supportingfixtu'rie' including.the:backing element 13 and the matrix :I 6 is -assembled in the opposite pairtof guides 14' and the complex surface. I 6a of. the: matrix 5 moved "intouengagee ment with .the machined surfacexofthez partly machined-blade. andthebacking: element .13 .then

lockedin place-bytightening of'theboltsi L. Y The fiat sided: support fixture then removed from the. block 'I 0 and. the remainingv flat Jside of :the partially finished impeller blade-is. then exposed for the next milling: operation; This is. the: condition generally illustrated 'in' Figure. 3-:of the drawings wherein is shown a' partiallyz machined workpieceifl mounted in the-chuck: H. has been-previously described; the:.backing:'element I3 is; shifted! radially inwardly from-the position shown in Figure 3 to bring the-exposed surface [6aof the: matrix I6 into snug engagementawith the complex surface vZlla. of the workpiece 20.

Hence, substantially all of the area ofth'e com v plex surfaceziiaof the :workpiece 2D is rigidly supported by abutment with the correspondingly shapedsurface Ilia of thematrix-v l6; Millingaor grinding operations may then be performed on the unfinished surface 20b, of the? blade :blank 20 to produce. withahi'gh degree-of accuracy, the finished complex contour 2 00' as "illustrated in Flgure' l; This contour can also be machined with ahigh degree of accuracy with respectto the centerof gravityof the rootfastening means of the blade.

In this connection, it should bepointed :out that one of the most-important-requirements in ma? chining these impeller blades is thatvthe location of the centerof gravityof each air foilsection coincide within Lrather. close limits .with the center'of gravity of the root fastehingcmeans of the blade. Since with the described method and apparatus, all of themachining operations on any particular blade maybe accomplished while the blade isfixedlysupportedin the'chuck'l 1 it is apparent that -thecomplex-"surfaces" thereon may be generated within veryclose-tolerance limits with respect to the center of gravity of the root fastening means; Furthermore,-theblock l0 may be successively mounted on apluralit'y or milling. or polishing machines iiwithout in any manner: effecting. the: locationsof" the .bladelawith respect .to .its supporting fixture.

Obviously, the aforedescribed work fixture may thereafter .be used for a large number of S1102- cessive workpieces, and is subject to deteriora+ tion only through wear by successive engagement with the workpieces.

The improvement .in accuracy of the machining of the second .vane surface of. impeller blades has been found to be quite substantial when a work supporting fixture-constructedin accordance with this invention is employed. The. fixture constructed in accordance with. this inven tion has the further advantage ofbeingextremely economical to fabricate, inasmuoh as no machining operationsare required and an entirely new fixture may be fabricated in the. matter of minutes. Furthermore, each matrix-lfi'which is produced. has uniquei-advantages-of being? exactly positioned. relative to the chuck ll, ;due to the locating-effectof the guides 14 upon the backing element 3. Anya-support fixture manufactured by conventional milling and igrindingioperations would require; after such ioperationaianextreme ly precise locating'ofithefcomplex suppo'rtin'gsiir face .with respeet :to the :ohuck 1H 7 Hence l the methods of this invention: result in' unusualecon omies: both in.productioniand to'oling costsui It will, of course,.'be understood thatlvari'ous details in construction or procedureimay be modifled: through'a wide range without' depar-tingefrom the principles of this invention, and it is, therefore, not the purpose'to-limiti thezpatentxgranted hereon otherwise than necessitatedz by the: scope of the: appended claims..-

Weclaim: 1 v

. 1. The method of providing workssupportfafor machining operations on successive identical work pieces, the workpieces having at least one ac curately formed surface thereon and:'a' mount ing portion at one end on1y*'thereof, which comprises rigidly'securing the mOUIltd 'IJOI'tiOIIE Ofi BJ master workpiece on *a machinetoolfixture'iln the machining location desired. for the succes-i sive workpieces, providing a single .rigidLback ing-element on the machine tool fixture .at: one 7 side only of the master workpiece andin': spaced relation to the surface of the master workpiece corresponding to the accurately formed surface of the successive workpieces; providingzazdamsin surrounding relation to a-spac'ea betweenisaid backing. element: and thermaster workpiece so that the'only'surface of the master'workpiec; that forms a boundary; for such space iSZ'EthBZaC- curately formed'surface thereof facing SELld'hEtCk-e: ing. element, filling said space :with' 'molten; 210w melting temperature material which issolid 'at ambient temperatures; removingf .saiduidamsand said master workpiecefrom the'machine tool fix-f ture, and successively andi rigidlyxsecuring the mounting portions of workpieces to said fixture for support on said fixture" in the placeof'the master workpiece, with the. accurately'i'formed surface 'of each workpiece engaged andisupported by said low melting temperature .materialdur ingmachiningoperations' thereon; A

2. A machine tool fixturefor rsupporting'a: thin, deformable workpiece having a complex surface opposite to thesurface to be machined? and: a mounting portion at one endithereofcompris; ingfa work support'block, a: single rigid I'backing' member secured to said block that isuthei s'ole' support member for the workpiece I'thattexten'ds beyond said: engaging means: 'on .said support blockin the samedirectionthe workpiec'efex tends, 'a matrix or. metal cast 1 onto said backing. member and having an exposed surface ther'eof molded to conform "to said complex. surface-.isof the'tworkpiece;v and a chuck unitilocated cen trallyi of said block for "receiving said mountiiig'i portion of said workpiece to rigidly-secur'esaid workpiece to said block with the complex surface thereof abutting" said molded surface of -t he' matrix.

3. A machine tool fixture forsupportingan impeller blade for machining operations on one. faceithereof, wherein the opposite 'faceofth'e' blade is of complex configuration and saidblade has 'a mounting portion only at one end,'co'm'- prising a support block, means on said support block for engaging said mounting portion of the bladeto rigidly. mount the blade thereon, Iasingle rigid-backing element that is' the sole supporting, member for the-blade engaging-1ymounted-on said:

support block-that extends beyond said engaging:

means-mu said support block-rin the:s ame-:idirec tion the blade extends, a matrix of metal cast on to said backing element and having an exposed surface thereof molded to conform to said complex face of the blade, and means including a slideway aligned with said blade engaging means for adjustably securing said backing element to saidsupport block, whereby said complex surface of the blade may be rigidly supported laterally solely by said molded surface of said matrix and vertically solely by said means engaging said mounting means.

4. A machine tool fixture for supporting an impeller blade for machining operations on one .face thereof, wherein the opposite face of the blade is of complex configuration and said blade has a mounting portion only at one end, comprising a support block, means in the center of said support block for rigidly engaging said mounting portion of the blade, means on said support block defining a radially extending slideway, a rigid backing member slidably supported in said slideway, a matrix of metal cast on to .said backing member and having an exposed surface thereof molded to conform to said complex surface of the blade, and means for adjustably securing said backing element to said support block, wherebysaid complex surface of the blade may be rigidly supported by the molded surface of said matrix.

5. The method ofmachining an impeller blade from a blank having opposed planar surfaces and root fastening means on one end thereof, which comprises rigidly attaching the blank to a machine tool fixture by the root fastening means, supporting one of said planar faces of the blank by a correspondingly shaped support member secured to the fixture while machining a complex surface on the opposed planar face, form-- ing a complex surface on a second support element corresponding to the complex surface machined on the blank, securing the second support element to the work fixture with its complex surface in juxtaposition with the machined complex surface on the blank, and machining the remaining planar face of the blank to the desired complex surface, whereby the opposed complex surfaces produced on the blank may be accurately generated with respect to the center of gravity of the root fastening means of the impeller blade.

6. The method of supporting a partially machined impeller blade for additional machining operations, said blade having when finished an :accurately machined complex airfoil section and :a mounting portion in gravitational alignment with the airfoil section thereof, which comprises rigidly and detachably supporting a master im-- peller blade on a machine tool fixture by engage-- ment of the blade mounting portion, providing a rigid backing element on said machine tool fixture at one side only of the master blade and in spaced relation to the surface of the masterblade corresponding to the machined surface of the partially machined impeller blades, providing a dam in surrounding relation to a space be-- tween said backing element and the master blade, so as to exclude the surface of the master blade: that faces away from said backing element, filling said space with molten, low melting tem-- perature material which is solid at ambient tem peratures, removing said dam and said master blade from the machine tool fixture, and rigidly mounting a partially machined blade on said fixture by engagement of the blade mounting portion, the blade airfoil section extending beyond"v 8 the fixture in cantilever axial gravitational aligxi= ment with the rigidly engaged mounting portion so that the airfoil portion of the blade is supported laterally solely by the engagement of the machined surface of the blade with said low melting temperature material.

7. A machine tool fixture for supporting a thin, deformable workpiece having a. complex surface opposite the surface to be machined, that comprises, as the sole support means for the workpiece, a support block having a generally planar face; a rigid backing element secured to said block and having a frontal generally planar face extending away from said block; a matrix of metal cast onto said backing element and having a frontal face molded to conform with the complex surface of the workpiece; and means on said block in front of the frontal face of said cast metal matrix for engaging and rigidly holding the workpiece at one of its ends to so position the workpiece that a plane passing through the workpiece generally parallel to the opposite surfaces thereof extends away from the planar face of said block and generally parallel to the frontal face of the backing element and in front of the frontal face of said metal matrix so that the complex surface of the workpiece abuts and is supported by the frontal face of said matrix and free access may be had to the opposite surface of the workpiece.

8. A machine tool fixture for supporting a thin, deformable workpiece having a complex surface opposite the surface to be machined, consisting of a support block having a generally planar face; a rigid backing element mounted on said block having a frontal generally planar face extending away from said block; a matrix of metal cast onto the frontal face of said backing element and having a frontal face molded to conform with the complex surface of the workpiece; a first means on said block in front of the frontal face of said matrix for engaging and rigidly holding the workpiece at one of its ends to so position the workpiece that a plane passing through the workpiece generally parallel to the opposite surfaces thereof extends away from the planar face of said block and generally parallel to the frontal face of said backing element and in front of the frontal face of said matrix; and adjustable means for securing said backing element to said block at a given distance from said first means along a line passing through said first means and generally normal to the frontal face of said backing element, so that the complex surface of the workpiece abuts and is supported by the frontal face of said matrix and free access may be had :to the opposite surface of the workpiece.

9. A machine tool fixture for supporting an impeller blade for machining operations on one face thereof, the opposite face of the blade having a complex configuration, consisting of a support block having a generally planar face; a rigid backing element mounted on said block having a frontal generally planar face extending away from said block and normal to the planar face of said block; a'matrix of metal cast onto said backing element having a frontal face molded to conform with the complex face of the blade; a first means in the center of said block and in front of the frontal face of said matrix for engaging and rigidly holding the blade at one end thereof to so position the blade that a plane passing through the blade and generally parallel to the opposite faces of the blade extends away from said block and normal to the planar face of said block and generally parallel to the frontal face of said backing element and in front of the frontal face of said matrix; and adjustable means forsecuring said backing element tosaid block at a given radial distance from said first means so that the complex face of the blade abuts and is supported by the frontal face of said matrix and free access may be had to the opposite face of the blade.

PIERCE T. ANGELL. CARL J. LESKA.

The following references are of record in the 10 REFERENCES CITED file of this patent:

5 UNITED STATES PATENTS Number Name Date -i 771,111 Abate Sept. 27, 1904 1,599,895 John Sept. 14, 1926 2,110,530 Saines Mar. 8, 1938 FOREIGN PATENTS Number Country Date 535,905 Germany Oct. 16, 1931 

